Seamless floor-to-wall transition assembly, kit, and method of installation thereof

Abstract

A seamless floor-to-wall transition assembly, kit, and method of installation having a plurality of cove panels which overlie the joint between a floor and a base of a wall, each having a curved outer surface which collectively form a seamless exterior surface, and a floor covering material sufficient to form a coating to cover the floor and abutting an outer free end of the cove panels, to provide a substantially smooth transition from floor covering material to cove panels. In clinical applications, the assembly also including at least one topcoat material which is sufficient to form a continuous coating to overlie the floor covering material and at least a portion of the cove panels, to provide a seamless transition between the floor covering material and the cove panels, which is easier to clean and minimizes crevices which can harbor dirt or germs leading to a more sanitary environment.

1 . A seamless floor-to-wall transition assembly, comprising:
 at least one cove panel which is configured and dimensioned to overlie a joint between a floor and a base of a wall, comprising a generally upright, upper leg having an upper free end and a lower end, and a generally horizontal, lower leg having an inner end joined to said lower end of said upper leg and an outer free end, said upper leg having an inner surface which is adapted to abut at least a portion of the wall, and said lower leg having a lower surface which is adapted to abut a portion of the floor generally adjacent to the base of the wall, said upper and lower legs each having an outer surface which merge together along a curved outer surface portion to collectively form a seamless exterior surface generally extending from said upper free end of said upper leg to said outer free end of said lower leg; and   at least one floor covering material which is curable from an initially flowable state to a cured state and sufficient to form a coating to cover at least a portion of the floor adjacent to said at least one cove panel such that, when in its cured state, said at least one floor covering material defines a lateral edge portion which abuts said outer free end of said lower leg and a top surface portion having a height which is generally equal to the height of said outer free end of said lower leg, to provide a substantially smooth transition from said top surface portion of said at least one floor covering material to said free end of said lower leg of said at least one cove panel.   
     
     
         2 . The assembly according to  claim 1 , further comprising:
 at least one topcoat material which is curable from an initially flowable state to a cured state, and which is sufficient to form a continuous coating to overlie said at least one floor covering material and at least a portion of said exterior surface of said at least one cove panel, to provide a seamless transition between said at least one floor covering material and said at least one cove panel.   
     
     
         3 . The assembly according to  claim 2 , wherein:
 said at least one topcoat material, when in its cured state, defines an outer peripheral edge which is disposed along the center of curvature of said curved outer surface portion of said exterior surface of said at least one cove panel.   
     
     
         4 . The assembly according to  claim 1 , wherein:
 said curved outer surface portion of said at least one cove panel is concaved.   
     
     
         5 . The assembly according to  claim 4 , wherein:
 said concaved curved outer surface portion of said at least one cove panel has a radius of about ½″.   
     
     
         6 . The assembly according to  claim 2 , wherein:
 said lower leg of said at least one cove panel is elongate and generally planar defining an extended lip portion, wherein said at least one topcoat material overlies at least a portion of said extended lip portion.   
     
     
         7 . The assembly according to  claim 1 , wherein:
 said upper leg of said at least one cove panel is disposed substantially 90 degrees from said lower leg of said at least one cove panel.   
     
     
         8 . The assembly according to  claim 1 , further comprising:
 a plurality of cove panels which are adapted to be joined together, such that said exterior surfaces of each of said cove panels collectively form a substantially seamless surface.   
     
     
         9 . The assembly according to  claim 8 , wherein:
 said plurality of cove panels are joined together by fusing.   
     
     
         10 . The assembly according to  claim 8 , wherein:
 said at least one of said cove panels is an inside corner cove panel.   
     
     
         11 . The assembly according to  claim 8 , wherein:
 said at least one of said cove panels is an outside corner cove panel.   
     
     
         12 . The assembly according to  claim 1 , wherein:
 said at least one cove panel is made of an acrylic solid surface material.   
     
     
         13 . The assembly according to  claim 1 , wherein:
 said at least one floor covering material is trowelable.   
     
     
         14 . The assembly according to  claim 1 , wherein:
 said at least one floor covering material is a resilient, urethane mortar comprising a urethane resin, a curing agent and a coarse rubber aggregate.   
     
     
         15 . The assembly according to  claim 2 , wherein:
 said at least one topcoat material is an aliphatic, polyaspartic urethane, and a non-reflective, waterborne, aliphatic polyurethane.   
     
     
         16 . The assembly according to  claim 1 , wherein:
 said outer free end of said lower leg is planar.   
     
     
         17 . The assembly according to  claim 1 , wherein:
 said outer free end of said lower leg has an irregular surface.   
     
     
         18 . The assembly according to  claim 1 , wherein:
 said outer free end of said lower leg has a mechanical interlock formed therein which engages with said at least one floor covering material.   
     
     
         19 . The assembly according to  claim 18 , wherein:
 said mechanical interlock is a member selected from the group consisting of a back cut, a bevel, a dado, a V-shaped groove, and a lap joint.   
     
     
         20 . The assembly according to  claim 1 , wherein:
 said at least one cove panel includes an angled chamfer section joining said lower end of said upper leg to said inner end of said lower leg.   
     
     
         21 . The assembly according to  claim 6 , wherein:
 said upper leg has a thickness of about ½″ and said extended lip portion has a length of about ⅜″ and a thickness of about ¼″.   
     
     
         22 . A method of providing a seamless floor-to-wall transition, comprising the steps of:
 providing at least one cove panel which is configured and dimensioned to overlie a joint between a floor and a base of a wall, comprising a generally upright, upper leg having an upper free end and a lower end, and a generally horizontal, lower leg having an inner end joined to said lower end of said upper leg and an outer free end, said upper leg having an inner surface which is adapted to abut at least a portion of the wall, and said lower leg having a lower surface which is adapted to abut a portion of the floor generally adjacent to the base of the wall, said upper and lower legs each having an outer surface which merge together along a curved outer surface portion to collectively form a seamless exterior surface generally extending from said upper free end of said upper leg to said outer free end of said lower leg; and at least one floor covering material which is curable from an initially flowable state to a cured state and sufficient to form a coating to cover at least a portion of the floor adjacent to said at least one cove panel such that, when in its cured state, said at least one floor covering material defines a lateral edge portion which abuts said outer free end of said lower leg and a top surface portion having a height which is generally equal to the height of said outer free end of said lower leg, to provide a substantially smooth transition from said top surface portion of said at least one floor covering material to said free end of said lower leg of said at least one cove panel;   arranging said at least one of cove panel to overlie the joint between the floor and the base of the wall, such that said inner surface of said upper leg abuts at least a portion of the wall and said inner surface of said lower leg abuts a portion of the floor generally adjacent to the base of the wall;   affixing said at least one cove panel to at least one of the wall and the floor;   applying said at least one floor covering material in its initial flowable state, sufficient to form a coating to cover at least a portion of the floor adjacent to said at least one cove panel; and   allowing said at least one floor covering material to cure, such that its cured state, said floor covering material defines a lateral edge portion which abuts said outer free end of said lower leg and a top surface portion having a height which is generally equal to the height of said outer free end of said lower leg, to provide a substantially smooth transition from said top surface portion of said at least one floor covering material to said free end of said lower leg of said at least one cove panel.   
     
     
         23 . The method according to  claim 22 , further comprising the steps of:
 providing at least one topcoat material which is curable from an initially flowable state to a cured state, and which is sufficient to form a continuous coating to overlie said floor covering material and at least a portion of said exterior surface of said at least one cove panel; and   applying said at least one topcoat material in its initial flowable state, sufficient to form a continuous coating to overlie said at least one floor covering material and at least a portion of said exterior surface of said at least one cove panel; and   allowing said at least one topcoat material to cure such that in its cured state, it provides a seamless transition between said at least one floor covering material and said at least one cove panel.   
     
     
         24 . The method according to  claim 22 , further comprises:
 providing a plurality of said cove panels which are adapted to be joined together.   
     
     
         25 . The method according to  claim 24 , further comprising:
 after said step of providing a plurality of said cove panels, joining said plurality of cove panels together, such that said exterior surfaces of each of said cove panels collectively form a substantially seamless surface.   
     
     
         26 . The method according to  claim 25 , wherein:
 said cove panels are joined in situ.   
     
     
         27 . The method according to  claim 24 , wherein:
 at least one of said cove panels is an inside corner cove panel.   
     
     
         28 . The method according to  claim 24 , wherein:
 at least one of said cove panels is an outside corner cove panel.   
     
     
         29 . The method according to  claim 24 , wherein:
 said plurality of cove panels are joined via an adhesive.   
     
     
         30 . A seamless floor-to-wall transition assembly kit, comprising:
 a plurality of cove panels which are configured and dimensioned to overlie a joint between a floor and a base of a wall, each comprising a generally upright, upper leg having an upper free end and a lower end, and a generally horizontal, lower leg having an inner end joined to said lower end of said upper leg and an outer free end, said upper leg having an inner surface which is adapted to abut at least a portion of the wall, and said lower leg having a lower surface which is adapted to abut a portion of the floor generally adjacent to the base of the wall, said upper and lower legs each having an outer surface which merge together along a curved outer surface portion to collectively form a seamless exterior surface generally extending from said upper free end of said upper leg to said outer free end of said lower leg, wherein said cove panels are adapted to be joined together, such that said exterior surfaces of each of said cove panels collectively form a substantially seamless surface;   at least one floor covering material which is curable from an initially flowable state to a cured state and sufficient to form a coating to cover at least a portion of the floor adjacent to said cove panels such that, when in its cured state, said at least one floor covering material defines a lateral edge portion which abuts said outer free end of said lower legs and a top surface portion having a height which is generally equal to the height of said outer free ends of said lower legs, to provide a substantially smooth transition from said top surface portion of said at least one floor covering material to said free ends of said lower legs of said cove panels; and   at least one topcoat material which is curable from an initially flowable state to a cured state, and which is sufficient to form a continuous coating to overlie said at least one floor covering material and at least a portion of said exterior surfaces of said cove panels, to provide a seamless transition between said at least one floor covering material and said cove panels.